Webroy

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MANUFACTURING QUALITY CHART

COMPILED BY		TEAM MEMBER 2
TEAM MEMBER 3		TEAM MEMBER 4
SUPPLIER	Webroy (Pty) Ltd	MQC No
CUSTOMER		REV No.
PART NAME		DATE INITIATED
PART No.		REVISION DATE	2023/02/08
		LAST REVIEW DATE
WEBROY STOCK CODE		STATUS
MANUFACTURING LOCATION	Webroy	SAFETY CRITICAL
MQC TYPE
Current

Process Flow Key

Process Type	Image
PARTS STOCK
COMPONENT PART
PROCESS OPERATION
SAMPLING INSPECTION
100% INSPECTION
TRANSPORT

Responsible
Confirmation Level Key

Name	Image
OPER
T/L
SUPERVISOR
MNGR
OPER
T/L
SUPERVISOR
MNGR

PROCESS FLOW	NO	NAME	WORK ELEMENT	CHECK ITEM	RANK	PROCESS CRITERION	INSPECTION METHOD	INSPECTION PLAN	FREQUENCY	Inspection No.(s)	Work Instructions	RESP	CHECK SHEET	CONFIRM'N LEVEL	REACTION PLAN
	1	Receiving and verification of raw material	Receiving	Receiving		Check for correct quantity delivered, Correct Material	Visual inspection and verification as per order	Delivery note and order	Every batch		1090		Goods receive notebook / delivery note		Should there be any discrepancies inform production planner / supplier immediately and make a note on P.O.D
	2	Move material to receiving storage area	Transport	Transport		Store material correctly	Visual inspection	As per FIFO system	Every batch				Visual inspection and FIFO board		If difficulty occurs in storing raw material properly inform Stores Coordinator
	3	Inspection of raw material by QA personnel	Inspection	Inspection		Mild Black Wire SAE 1008 Part No. WIRE/MBH2/0500 Correct diameter = 5mm +/- 0.08. No score marks - no rusty wire. Correct tensile 500 to 750 mpa Verify material compositions	Visual inspection Micrometer for wire diameter COA from supplier - record findings on incoming inspection document	As per incoming raw material inspection QD207	Every consignment	1059	1120		Goods receive notebook / Buff tag and record findings on incoming receiving inspection no. 1059		Any non-conforming raw material shall be placed on hold and isolated. Raise SRAN and inform Stores Coordinator
	4	Move raw material to dedicated area forstorage	Storage	Storage		Safe stacking of wire coils on to racks as per allocated areas and FIFO system	Visual inspection	As per FIFO system	On receiving				FIFO information board and rack identification		Any difficulty experienced during this activity report to Stores Coordinator
	5	Issue wire to production	Issuing	Issuing	SC	Correct wire to be issued as per job card	Verification as per buff tag Setter to measure wire diameter with vernier	Every coil issued to production	Every coil				Route card		Should the incorrect wire be issued to production stop process, correct and inform Stores Coordinator
	6	Cut Wire to length	Cut Wire	Cut Wire	SC	Cut wire to length 223mm +- 1mm	Visual inspection Tape Measure to measure length	First-off sample In-process inspection	First-off at start of production. In-process 1 part every hour and last off	1061 2061	1068		Record first-off and in-process inspection on BIS card		Should the first-off sample fail stop process and reset machine and re-do first-off
	7	Sub contract chamfer and machine grooves	Sub Contract	Straight Wires	SC	Chamfer placement and angle Grove placement and angle	Visual Inspection	Every batch	Every batch				NA		Any difficulty report to the Webroy Production Manager
	8	Receive chamfer & grooved part from sub contractor	Receiving	Chamfered & Groove Part		Chamfer and groove position and angle	Visual Inspection	Sample Inspection during receiving	Every batch	1063			Receiving Inspection Sheet		Any issues report to Production Manager and Quality Supervisor
	9	Issue chamfered and grooved wire to production	Issuing	Sub-Component Part		Correct sub-component as per router card	Visual Inspection	Check part and qty issued against route card	Every batch				Route Card		If difficulty during this process report to Stores Supervisor and/or Production Supervisor
	10	Form part on bending machine	Bending	Wire	SC	Bend as per drawing. Correct bends/rotate. Parts shall drop fit into checking fixture. The part must sit flat in the fixture and have no gaps, the part must not fit higher then the pins. Measure height of leg which shall be between 8mm - 9mm. Check locking bolt for sensor is not stripped/worn.	100% visual inspection of correct fitment and measure leg height with a vernier.	First off inspection In process inspection Last-off	100% visual inspection.	1073 2063 15427 1064 2062 15426	1067		record on online inspections.		Any difficulty during bending, stop report to Production Supervisor. For any stoppages a new first-off shall be done to re-qualify th e production run.
	11	Send parts for Electro Plating	Electro Plating	Bent parts		Surface and Heat Treatment as per TSH6524G-BC	Visual inspection	Every batch	Every batch				N/A		Any difficulty report to Production Manager
	12	Receive Electro plated parts	Receiving	Electro plated parts		Surface and Heat treatment as per TSH6524G-BC. Surface finish must be bright/shiny with no visible damage or marks	Visual inspection	Every batch	Every batch	1065			N/A		Any issues report to Quality supervisor and Production manager
	13	Apply Paint I.D	Paint I.D	Painted Part		69311-0A090 - Apply Orange Paint I.D. and 69312-0A100 - Apply Green Paint I.D	Visual verification	First-off, In-process inspection and Last off	Every batch	1066 2064 1075 2065	1088		Record every hour on BIS Card		Any difficulty report to supervisor
	14	Transport product to stores	Transport	Transport		Use plastic bin size 4311 Place 300 parts in each box	Visual inspection	As per works order	Every batch				F/A Card		Should difficulty occur during transport inform Supervisor
	15	Receipting product to stores	Receipting	Receipting		Correct quantity to be entered on to the stock system	Visual	Every batch	Every order		1094		F/A Card		Any discrepancies shall be reported to the Stores Coordinator
	16	Packing of final product	Packing	Packing		Correct quantity per bin Correct bin	Visual	As per work instruction	Every job				F/A Card		Should the quantity be incorrect, stop process, verify quantity and add/remove products to meet quantity required
	17	Dispatching of products	Transport	Transport		Correct loading of bins and safe handling during transport activity	Visual	Entire order	Every order		1101		Delivery note / invoice		Any difficulty experienced during this activity report to Stores Coordinator
	18	Layout functional inspection	Inspection	Inspection	SC	Full dimensiomal	As per customer requiremetns	1 Complete product	As per schedule				Audit sheet		Should the functional layout fail the Production manager shall be informed immediately.